U.S. patent number 8,980,060 [Application Number 12/443,515] was granted by the patent office on 2015-03-17 for biomass hydrothermal decomposition apparatus, method thereof, and organic material production system using biomass material.
This patent grant is currently assigned to Mitsubishi Heavy Industries Mechatronics Systems, Ltd.. The grantee listed for this patent is Isao Ishida, Seiji Kobayashi, Hideo Suzuki, Seiichi Terakura. Invention is credited to Isao Ishida, Seiji Kobayashi, Hideo Suzuki, Seiichi Terakura.
United States Patent |
8,980,060 |
Ishida , et al. |
March 17, 2015 |
Biomass hydrothermal decomposition apparatus, method thereof, and
organic material production system using biomass material
Abstract
A biomass hydrothermal decomposition apparatus includes, a
biomass feeder (31) that feeds biomass material (11) under normal
pressure to under increased pressure, a hydrothermal decomposition
device (42A) that allows the fed biomass material (11) to be
gradually moved inside a device main body (42A) from either end
thereof in a consolidated condition, and also allows hot compressed
water (15) to be fed from an other end of a feed section for the
biomass material into the main body (42A), so as to cause the
biomass material (11) and the hot compressed water (15) to
countercurrently contact with each other and undergo hydrothermal
decomposition, and that elutes a lignin component and a
hemicellulose component into the hot compressed water, so as to
separate the lignin component and the hemicellulose component from
the biomass material (11); and a biomass discharger (51) that
discharges, from the side where the hot compressed water is fed
into the device main body, a biomass solid residue (17) under
increased pressure to under normal pressure.
Inventors: |
Ishida; Isao (Hyogo,
JP), Terakura; Seiichi (Hyogo, JP), Suzuki;
Hideo (Hyogo, JP), Kobayashi; Seiji (Hyogo,
JP) |
Applicant: |
Name |
City |
State |
Country |
Type |
Ishida; Isao
Terakura; Seiichi
Suzuki; Hideo
Kobayashi; Seiji |
Hyogo
Hyogo
Hyogo
Hyogo |
N/A
N/A
N/A
N/A |
JP
JP
JP
JP |
|
|
Assignee: |
Mitsubishi Heavy Industries
Mechatronics Systems, Ltd. (Kobe, JP)
|
Family
ID: |
40912424 |
Appl.
No.: |
12/443,515 |
Filed: |
September 19, 2008 |
PCT
Filed: |
September 19, 2008 |
PCT No.: |
PCT/JP2008/067038 |
371(c)(1),(2),(4) Date: |
March 30, 2009 |
PCT
Pub. No.: |
WO2009/096060 |
PCT
Pub. Date: |
August 06, 2009 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20100184176 A1 |
Jul 22, 2010 |
|
Foreign Application Priority Data
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|
|
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Feb 1, 2008 [JP] |
|
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2008-023188 |
|
Current U.S.
Class: |
162/233; 162/223;
162/248; 241/28; 162/1; 241/21; 241/38; 241/20; 162/244;
162/234 |
Current CPC
Class: |
C10L
9/086 (20130101); C08B 37/0057 (20130101); C12P
7/10 (20130101); B09B 3/0083 (20130101); C12M
21/12 (20130101); B09B 3/00 (20130101); C10L
5/44 (20130101); B01D 11/0226 (20130101); C08H
6/00 (20130101); C12M 45/02 (20130101); C12M
45/20 (20130101); Y02E 50/16 (20130101); Y02E
50/10 (20130101); C12P 2201/00 (20130101); Y02E
50/30 (20130101); Y02E 50/17 (20130101) |
Current International
Class: |
B02C
11/08 (20060101); B02C 21/00 (20060101); D21C
7/00 (20060101) |
Field of
Search: |
;435/290.1,290.2,290.4,291.1,291.7 ;71/11,14,15
;162/1,223,234,244,248,250 ;241/20,21,28,38 |
References Cited
[Referenced By]
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Aug 2009 |
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WO |
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2009/124240 |
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Oct 2009 |
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WO |
|
2010/038302 |
|
Apr 2010 |
|
WO |
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|
Primary Examiner: Bowers; Nathan
Attorney, Agent or Firm: Westerman, Hattori, Daniels &
Adrian, LLP
Claims
The invention claimed is:
1. A biomass hydrothermal decomposition apparatus comprising: a
biomass feeder having a piston pump for pressing biomass material
so as to make the biomass material consolidated and feeding the
consolidated biomass material via a valve; a hydrothermal
decomposition device including: a device main body for
countercurrently contacting the consolidated biomass material with
a decomposition liquid essentially consisting of hot compressed
water and hydrothermally decomposing the consolidated biomass, so
as to elute a lignin component and a hemicellulose component into
the hot compressed water and separate the lignin component and the
hemicellulose component from the consolidated biomass material, a
biomass material inlet provided on one side of the device main
body, for supplying the consolidated biomass material into the
device main body, a hot compressed water inlet provided on other
side of the device main body, for supplying the decomposition
liquid into the device main body, a discharged hot water outlet
provided on the one side of the device main body, for discharging
the hot compressed water with the lignin component and the
hemicellulose component as a discharged hot water from the device
main body, and a biomass solid residue outlet provided on the other
side of the device main body, for discharging a biomass solid
residue from the device main body, a biomass discharger that
discharges the biomass solid residue from the biomass solid residue
outlet under increased pressure to a decreased pressure, wherein
the hydrothermal decomposition device further includes an excess
water removal line for supplying a part of the discharged hot water
as an excess water from the downstream of the discharged hot water
outlet with respect to a flow direction from the hot compressed
water inlet to the discharged hot water outlet to upstream of the
biomass feeder, the hydrothermal decomposition device has a
reaction temperature ranging from 180.degree. C. to 240.degree. C.
and has a condition of hot compressed water; wherein a weight ratio
of the fed consolidated biomass material and the fed hot compressed
water is within 1:1 to 1:10; wherein a pressure higher by 0.1 MPa
to 0.5 MPa is added to saturated vapor pressure of water at each
temperature of the reaction temperature; wherein a reaction time is
not more than 20 minutes; and wherein the consolidated biomass
material are moved from the biomass material inlet to the biomass
solid residue outlet by the piston pump.
2. The biomass hydrothermal decomposition apparatus according to
claim 1, further comprising a fixed stirring unit or a rotating
stirring unit that stirs the consolidated biomass material inside
the device main body, wherein the rotating stirring unit has a
rotation axis and a plurality of rotatable paddles that are
provided at predetermined intervals of the rotation axis.
3. The biomass hydrothermal decomposition apparatus according to
claim 1, further comprising: another hot compressed water inlet for
supplying the decomposition liquid into the device main body; and a
discharged hot water outlet for discharging the hot compressed
water from the device main body.
4. The biomass hydrothermal decomposition apparatus according to
claim 1, further comprising a filter section that filtrates the
discharged hot water to be discharged from the device main body,
the filter section being provided upstream of the discharged hot
water outlet and in the device main body.
5. The biomass hydrothermal decomposition apparatus according to
claim 1, further comprising a density monitoring unit that detects
a weight of a biomass solid residue content inside the device main
body.
6. The biomass hydrothermal decomposition apparatus according to
claim 2, wherein the rotating stirring unit includes a scraper that
prevents occlusion of the discharged hot water outlet.
7. The biomass hydrothermal decomposition apparatus according to
claim 1, wherein the hydrothermal decomposition apparatus is a
gradient type or a vertical type.
8. The biomass hydrothermal decomposition apparatus according to
claim 1, wherein the biomass solid residue is suitable as a raw
material for saccharification.
9. The biomass hydrothermal decomposition apparatus according to
claim 1, wherein the biomass feeder further comprises a water
feeding apparatus for feeding water therein.
10. The biomass hydrothermal decomposition apparatus according to
claim 1, wherein the device main body has a taper shape whose
cross-sectional area decreases from the biomass material inlet to
the biomass solid residue outlet.
11. The biomass hydrothermal decomposition apparatus according to
claim 1, wherein the biomass discharger includes a compressing
mechanism for compressing the biomass solid residue so as to remove
residual water from the biomass solid residue and a residual water
outlet for discharging the residual water.
12. A method for biomass hydrothermal decomposition comprising:
pressing biomass material so as to make the biomass material
consolidated and feeding the consolidated biomass material;
supplying the consolidated biomass material into a device main body
of a hydrothermal decomposition device; supplying a decomposition
liquid essentially consisting of hot compressed water into the
device main body; countercurrently contacting the consolidated
biomass material with the decomposition liquid and hydrothermally
decomposing the consolidated biomass, so as to elute a lignin
component and a hemicellulose component into the hot compressed
water and separate the lignin component and the hemicellulose
component from the consolidated biomass material, discharging the
hot compressed water with the lignin component and the
hemicellulose component as a discharged hot water from the device
main body, and discharging a biomass solid residue from the device
main body, discharging the biomass solid residue from an increased
pressure to a decreased pressure, wherein the method further
comprising supplying a part of the discharged hot water as an
excess water to the biomass material before making the biomass
material consolidated, a reaction temperature of the hydrothermal
decomposition ranges from 180.degree. C. to 240.degree. C. and an
interior of the device is in a condition of hot compressed water;
wherein a weight ratio of the fed consolidated biomass material and
the fed hot compressed water is within 1:1 to 1:10; wherein a
pressure higher by 0.1 MPa to 0.5 MPa is added to saturated vapor
pressure of water at each temperature of the reaction temperature;
wherein a reaction time is not more than 20 minutes and wherein the
pressing biomass material causes the consolidated biomass material
in the device main body to move from the biomass material inlet to
the biomass solid residue outlet.
13. The method according to claim 12, wherein the biomass solid
residue is suitable as a raw material for saccharification.
14. An organic material production system using biomass material,
the organic material production system comprising: a pretreatment
device that pretreats the biomass material; the hydrothermal
decomposition apparatus according to claim 1; a first enzymatic
hydrolysis device that treats, with an enzyme, cellulose in a
biomass solid residue discharged from the hydrothermal
decomposition device, so as to enzymatically hydrolyze the
cellulose to a sugar solution containing hexose; and a fermenter
that produces, using the sugar solution obtained by the first
enzymatic hydrolysis device, any one of alcohols, substitutes for
petroleum, or amino acids by fermentation.
15. The organic material production system using biomass material
according to claim 14, comprising: a second enzymatic hydrolysis
device that treats, with an enzyme, a hemicellulose component in
discharged hot water, so as to enzymatically hydrolyze the
hemicellulose component to a sugar solution containing pentose; and
a fermenter that produces, using the sugar solution obtained by the
second enzymatic hydrolysis device, any one of alcohols,
substitutes for petroleum, or amino acids by fermentation.
Description
TECHNICAL FIELD
The present invention relates to a biomass hydrothermal
decomposition apparatus and a method thereof that enable efficient
hydrothermal decomposition of biomass material, and to an organic
material production system using biomass material, which system
enables efficient production of organic materials such as alcohols,
substitutes for petroleum, or amino acids by using such apparatus
and method.
BACKGROUND ART
Technologies for producing ethanol or the like have been
commercialized that involve converting woody biomass or other
biomass into sugars with dilute sulfuric acid or concentrated
sulfuric acid, and then subjecting them to solid-liquid separation,
neutralizing the liquid phase thereof, and utilizing the resultant
components as biomass materials for ethanol fermentation or the
like (Patent Documents 1 and 2). Further, by using sugar as
starting material, production of chemical industrial raw material
(e.g., lactic fermentation) has been considered. Biomass as used
herein refers to a living organism integrated in material
circulation in the global biosphere or accumulation of organic
materials derived from living organisms (see JIS K 3600 1258).
Sugarcane, corn, and other materials, currently used as alcohol raw
materials, have been originally used for food. Using such food
resources as long-term stable industrial resources is not
preferable in view of life cycle of valuable food.
For this reason, it is a challenge to efficiently use cellulose
resources such as herbaceous biomass and woody biomass, which are
considered as potentially useful resources.
Cellulose resources include cellulose ranging from 38% to 50%,
hemicelluloses components ranging from 23% to 32%, and lignin
components, which are not used as fermentation materials, ranging
from 15% to 22%. Due to many challenges, the industrial studies
have been conducted targeting certain fixed materials, and no
technologies have been disclosed yet on production systems taking
into account diversity of the materials.
Production systems targeting fixed materials see almost no point
regarding countermeasures for waste problems and global warming,
because those systems have attempted such countermeasures with a
method that brings more disadvantages to fermentation materials
than starch materials. Thus, there has been a need for a method
applicable to a variety of wastes in broader sense. Enzymatic
saccharification methods are also considered as a future challenge
due to its low efficiency. Acid treatment only achieves a low
saccharification rate of about 75% (a basis for components that can
be saccharified), due to excessive decomposition of sugar. Thus,
the ethanol yield achieves only 25% by weight of cellulose
resources (Non-Patent Document 1 and Patent Document 3).
[Patent Document 1] Japanese Patent Application Laid-open No.
9-507386
[Patent Document 2] Japanese Patent Application Laid-open No.
11-506934
[Patent Document 3] Japanese Patent Application Laid-open No.
2005-168335
[Non-Patent Document 1] Nikkei Biotechnology & Business, p. 52,
September 2002
[Non-Patent Document 2] Biomass-Extensive Use of Bioresources,
edited by Japanese Society for Bioscience, Biotechnology, and
Agrochemistry, Asakura Publishing Co., Ltd., September 1985
DISCLOSURE OF INVENTION
Problem to be Solved by the Invention
In the proposals disclosed in Patent Documents 1 and 2 above,
sulfuric acid necessary for reaction needs to be constantly
supplied from outside the reaction system. With increasing the
production scale, this poses problems, such as increasing the cost
for purchasing equipment resistant to the acid and large amounts of
sulfuric acid, while increasing the cost for disposing used
sulfuric acid (e.g., cost for processing with a gypsum
desulfulation), and the cost for recovering such sulfuric acid.
The proposal disclosed in Patent Document 3 above involves
subjecting various types of cellulose resources to hydrothermal
treatment, and converting them into sugars with enzymatic
saccharification. During the hydrothermal treatment, cellulase
inhibitors such as lignin components (Non-Patent Document 2) that
inhibit enzymatic saccharification of cellulose are not removed and
mixed with cellulose. This poses a problem of reducing the
efficiency in cellulose enzymatic saccharification.
Other than cellulose, hemicellulose components are also contained
in cellulose resources. This poses a problem that enzymes suitable
for cellulose and hemicellulose components are necessary for
enzymatic saccharification.
The resulting sugar solution includes a hexose solution from
cellulose, and a pentose solution from hemicellulose components.
For example, for alcohol fermentation, yeasts suitable for the
respective solutions are necessary. Thus, alcohol fermentation
needs to be improved low efficiency for fermenting a mixture of a
hexose solution and a pentose solution.
As such, conventional technologies have caused a phenomenon that
side reaction products inhibit enzymatic saccharification, reducing
the sugar yield. Thus, what has been needed is a hydrothermal
decomposition apparatus that removes inhibitors for enzymatic
saccharification and thereby improves enzymatic saccharification of
cellulose-based components.
In view of the foregoing problems, the present invention has an
object to provide: a biomass hydrothermal decomposition apparatus
and a method thereof that enable separation of cellulose-based
components from biomass material; and an organic material
production system using biomass material, which can efficiently
produce a sugar solution using such apparatus and method, and can
efficiently produce various types of organic materials (e.g.,
alcohols, substitutes for petroleum, or amino acids) using the
sugar solution as a base material.
Means for Solving Problem
According to an aspect of the present invention, a biomass
hydrothermal decomposition apparatus includes a biomass feeder that
feeds biomass material under normal pressure to under increased
pressure, a hydrothermal decomposition device that allows the fed
biomass material to be gradually moved inside a device main body
from either end thereof in a consolidated condition, and also
allows hot compressed water to be fed from an other end of a feed
section for the biomass material into the main body, so as to cause
the biomass material and the hot compressed water to
countercurrently contact with each other and undergo hydrothermal
decomposition, and that elutes a lignin component and a
hemicellulose component into the hot compressed water, so as to
separate the lignin component and the hemicellulose component from
the biomass material; and a biomass discharger that discharges,
from the side where the hot compressed water is fed into the device
main body, a biomass solid residue under increased pressure to
under normal pressure.
Advantageously, the biomass hydrothermal decomposition apparatus
further include a fixed stirring unit or a rotating stirring unit
that stirs the biomass material inside the device main body.
Advantageously, in the biomass hydrothermal decomposition
apparatus, the biomass feeder is a pressing unit that presses the
biomass.
Advantageously, the biomass hydrothermal decomposition apparatus
further includes an excess water drain line through which excess
water is drained from pulverized biomass to be fed into the device
main body.
Advantageously, the biomass hydrothermal decomposition apparatus
further includes
a plurality of feed sections through which the hot compressed water
is fed into the device main body, and a plurality of discharge
sections through which discharged hot water is discharged from the
device main body.
Advantageously, the biomass hydrothermal decomposition apparatus
further includes a filter section that filtrates the discharged hot
water to be discharged from the device main body.
Advantageously, the biomass hydrothermal decomposition apparatus
further includes a density monitoring unit that monitors a biomass
solid residue content inside the device main body.
Advantageously, in the biomass hydrothermal decomposition
apparatus, the rotating stirring unit includes a scraper that
prevents occlusion of an outlet for discharged hot water.
Advantageously, in the biomass hydrothermal decomposition
apparatus, the hydrothermal decomposition device has a reaction
temperature ranging from 180.degree. C. to 240and has a condition
of hot compressed water.
Advantageously, in the biomass hydrothermal fed biomass material
and the fed hot compressed water is within 1:1 to 1:10.
According to another aspect of the present invention, a method for
biomass hydrothermal decomposition includes feeding biomass
material under normal pressure to under increased pressure,
allowing the fed biomass material to be gradually moved inside a
device main body from either end thereof in a consolidated
condition and allowing hot compressed water to be fed from an other
end of a feed section for the biomass material into the main body,
so as to cause the biomass material and the hot compressed water to
countercurrently contact with each other and undergo hydrothermal
decomposition, eluting a lignin component and a hemicellulose
component into the hot compressed water, so as to separate the
lignin component and the hemicellulose component from the biomass
material, and discharging, from the side where the hot compressed
water is fed into the device main body, a biomass solid residue
under increased pressure to under normal pressure.
According to still another aspect of the present invention, an
organic material production system using biomass material includes
a pretreatment device that pretreats the biomass material, the
hydrothermal decomposition apparatus according to any one of the
first to tenth inventions, a first enzymatic hydrolysis device that
treats, with an enzyme, cellulose in a biomass solid residue
discharged from the hydrothermal decomposition device, so as to
enzymatically hydrolyze the cellulose to a sugar solution
containing hexose; and a fermenter that produces, using the sugar
solution obtained by the first enzymatic hydrolysis device, any one
of alcohols, substitutes for petroleum, or amino acids by
fermentation.
Advantageously, the organic material production system using
biomass material includes a second enzymatic hydrolysis device that
treats, with an enzyme, a hemicellulose component in discharged hot
water, so as to enzymatically hydrolyze the hemicellulose component
to a sugar solution containing pentose, and a fermenter that
produces, using the sugar solution obtained by the second enzymatic
hydrolysis device, any one of alcohols, substitutes for petroleum,
or amino acids by fermentation.
EFFECT OF THE INVENTION
According to the present invention, with use of a hydrothermal
decomposition apparatus that causes biomass material and hot
compressed water to countercurrently contact with each other in a
consolidated condition, side reaction products (lignin components
and hemicellulose components) resulting from the reaction for
producing a target component, i.e., cellulose, (that is
enzymatically saccharified to a hexose solution) are transferred
into the hot compressed water. In this way, the cellulose-based
biomass solid residue can be obtained. Accordingly, by efficiently
saccharifying it to the hexose solution and using the sugar
solution as a substrate material, various types of organic
materials (e.g., alcohols, substitutes for petroleum, or amino
acids) can be produced efficiently.
By causing biomass material and hot compressed water to
countercurrently contact with each other, their components are
sequentially discharged to the outside the reaction system in order
of solubility in the hot water. Further, due to the temperature
gradient from a portion where the biomass is fed to a portion where
the hot water is fed, excessive decomposition of hemicellulose
components is prevented. As a result, pentose components can be
recovered efficiently.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic of a hydrothermal decomposition apparatus
according to a first embodiment.
FIG. 2 is a schematic of another hydrothermal decomposition
apparatus according to a first embodiment.
FIG. 3 is a schematic of another hydrothermal decomposition
apparatus according to a first embodiment.
FIG. 4 is a schematic of another hydrothermal decomposition
apparatus according to a first embodiment.
FIG. 5 is a schematic of another hydrothermal decomposition
apparatus according to a first embodiment.
FIG. 6 is a schematic of another hydrothermal decomposition
apparatus according to a first embodiment.
FIG. 7 is a schematic view of a biomass feeder according to the
first embodiment.
FIG. 8 is a schematic view of another biomass feeder according to
the first embodiment.
FIG. 9 is a graph of temperature distribution in a reactor.
FIG. 10 is a schematic of an alcohol production system according to
a second embodiment.
FIG. 11 is a schematic of an alcohol production system according to
a third embodiment.
EXPLANATIONS OF LETTERS OR NUMERALS
10-1, 10-2 alcohol production system
11 biomass material
12 pretreatment device
13 pulverized biomass
41-1A to 41-1C,41-2, 41-3 hydrothermal decomposition device
15 hot compressed water
16 discharged hot water
17 biomass solid residue
18 enzyme
19 enzymatic hydrolysis device
19-1 first enzymatic hydrolysis device
19-2 second enzymatic hydrolysis device
20-1 first sugar solution (hexose)
20-2 second sugar solution (pentose)
23 ethanol
BEST MODE(S) FOR CARRYING OUT THE INVENTION
Exemplary embodiments of the present invention are described with
reference to the accompanying drawings. The present invention is
not limited to the embodiments. Constituting elements in the
embodiments include elements easily achieved by a person skilled in
the art, or elements being substantially equivalent to those
elements.
First Embodiment
A biomass hydrothermal decomposition apparatus according to an
embodiment of the present invention is described with reference to
the drawings. FIG. 1 is a schematic of a biomass hydrothermal
decomposition apparatus according to the embodiment. As shown in
FIG. 1, a biomass hydrothermal decomposition apparatus 41-1A
according to the present embodiment includes: a biomass feeder 31
that feeds biomass material (e.g., straw in the present embodiment)
11 under normal pressure to under increased pressure; a horizontal
device main body (hereinafter, "device main body") 42A that allows
the fed biomass material 11 to be gradually moved therethrough from
an end on either the left or the right side (on the left side in
the present embodiment) thereof in a consolidated condition, and
also allows hot compressed water 15 to be fed therein from an end
(on the right side in the present embodiment), which is different
from the side from which the biomass material 11 is fed, so as to
cause the biomass material 11 and the hot compressed water 15 to
countercurrently contact with each other and undergo hydrothermal
decomposition, and that transfers lignin components and
hemicellulose components into the hot compressed water 15, so as to
separate the lignin components and the hemicellulose components
from the biomass material 11; and a biomass discharger 51 that
discharges a biomass solid residue 17 under increased pressure to
under normal pressure, at the side from which the hot compressed
water 15 is fed into the device main body 42A. Examples of the
biomass feeder 31 that feeds biomass under normal pressure to under
increased pressure may include a pump unit such as a piston pump or
a slurry pump.
In the present embodiment, inside the device main body 42A is
provided a fixed stirring unit 61-1 that stirs the biomass material
11 in a consolidated condition, so called in plug flow. With this
arrangement, the biomass material 11 fed therein is stirred by
stirring action when moved axially.
By providing the fixed stirring unit 61-1, the pressurized water on
the surface of the solid and inside the solid is progressively
mixed in the device main body 42A, so that the reaction is
facilitated.
According to the present invention, for the flowage of the hot
compressed water 15 and the flowage of the biomass material 11
inside the device main body 42A of the hydrothermal decomposition
apparatus 41-1A, the hot compressed water 15 and the biomass
material 11 are countercurrently contacted, preferably with
agitated flow.
The hydrothermal decomposition apparatus 41-1A performs
decomposition in plug flow and has a simple configuration. Thus,
the solid, the biomass material 11 is moved parallel to a central
axis of its pipe, while being stirred in a direction perpendicular
to the central axis of the pipe. On the contrary, the hot
compressed water 15 (hot water, the liquid dissolving decomposed
products) is moved while being soaked in solid particles by the
counter-current flow against the solid.
In the plug flow, the hot compressed water 15 is flowed uniformly.
This is because, when the solid biomass material 11 is decomposed
in the hot compressed water 15, the decomposed products are
dissolved in the hot water. Accordingly, the viscosity around a
decomposed portion is increased, so that the hot water is moved
toward an undecomposed portion dominantly, causing decomposition of
the undecomposed portion. This creates a uniform flow of the hot
water, enabling uniform decomposition.
In the device main body 42A of the hydrothermal decomposition
apparatus 41-1A, due to the resistance of its inner pipe wall, the
solid density at the outlet side for the biomass material 11 is
reduced compared with that at the inlet side for the biomass
material 11. In addition, the amount of the biomass solid residue
17 is reduced by the decomposition. As a result, the ratio of the
hot compressed water 15 is increased, and the liquid retention time
is prolonged, causing excessive decomposition of decomposed
components in the liquid. For this reason, the fixed stirring unit
can be provided as appropriate.
The fixed stirring unit 61-1 may have grooves formed thereon, or
may be installed at various pitches. Further, the fixed stirring
unit 61-1 may have screws in series at multiple stages, so that
each screw performs stirring individually. The device main body 42A
of the hydrothermal decomposition apparatus 41-1A may have a taper
shape. Specifically, in the device main body 42A, the outlet for
the biomass material 11 may have a smaller cross-sectional area
than the inlet. With this arrangement, the solid density of the
biomass material 11 is increased in the device main body 42A.
Further, an unstiffing function may be provided for preventing the
solid from occluding the device main body 42A. Further, the
solid-liquid weight ratio in the device main body 42A may be
controlled appropriately by controlling, for example, the torque of
a rotating stirring unit, the capacitance and the ultrasonic wave
in the device main body 42A, and the weight of components inside
the device main body 42A.
Biomass to be fed to the hydrothermal decomposition apparatus 41-1A
is not limited to any specific type, and is a living organism
integrated in material circulation in global biosphere or
accumulation of organic materials derived from living organisms
(see JIS K 3600 1258). In the present invention, particularly,
cellulose resources of wood materials such as broadleaf trees and
plant materials; agricultural wastes; and food wastes are
preferably used.
The biomass material 11 is preferably broken into particles having
a diameter of 5 millimeters or less, though not limited to this
particle diameter. In the present embodiment, biomass may be
subjected to pretreatment with pretreatment equipment such as
pulverizing equipment, before being fed. In addition, biomass may
be cleaned with cleaning equipment. When the biomass material 11 is
rice husk, for example, the biomass material 11 can be fed to the
hydrothermal decomposition apparatus 41-1A, without being subjected
to pulverization.
In the hydrothermal decomposition apparatus 41-1A, the reaction
temperature ranges from 180.degree. C. to 240.degree. C.
preferably, and from 200.degree. C. to 230.degree. C. more
preferably. This is because, at temperatures below 180.degree. C.,
the hydrothermal decomposition takes place at a low rate and
requires a longer time, increasing the apparatus size, which are
not preferable. On the contrary, at temperatures above 240.degree.
C., the decomposition rate is too high and more cellulose
components are transferred from the solid phase to the liquid
phase, facilitating excessive decomposition of hemicellulose
sugars, which are not preferable. Dissolution of hemicellulose
components starts at about 140.degree. C., dissolution of cellulose
starts at about 230.degree. C., and dissolution of lignin
components starts at about 140.degree. C. The temperature is
preferably set within a range from 180.degree. C. to 240.degree. C.
that allows cellulose to be remained in the biomass solid residue,
and that enables hemicellulose components and lignin components to
be decomposed at adequate rates.
The reaction pressure is preferably set to a pressure higher by 0.1
MPa to 0.5 MPa than the saturated vapor pressure of water at each
temperature, which allows the hot compressed water to stay inside
the device main body. The reaction time is preferably three minutes
to ten minutes, not more than 20 minutes. This is because a longer
reaction time increases the ratio of excessively decomposed
products and is not preferable.
For these reasons, preferably, the hydrothermal decomposition
apparatus 41-1A creates a uniform flow of hot compressed water
while causing the biomass material 11 and the hot compressed water
15 to countercurrently contact with each other.
The hot compressed water 15 is flowed by the counter-current flow,
so that the heat is directly exchanged. This results in a
temperature distribution as shown in FIG. 9, preventing excessive
decomposition of decomposed products (such as lignin components),
which are decomposed and discharged into the liquid.
The hot compressed water 15 to be fed into the device main body 42A
is preferably less in weight relative to the biomass material 11,
because it enables reduction in amount of steam used for warming
during the hydrothermal decomposition. The weight ratio of the
biomass material 11 and the hot compressed water 15 both to be fed
is, for example, 1:1 to 1:10 preferably, and 1:1 to 1:5 more
preferably, though it varies accordingly depending on the apparatus
configuration. Particularly, in the present embodiment, the plug
flow is composed of solid phase and liquid phase, i.e. the biomass
material 11 and the hot compressed water 15, and is moved through
the device main body 42A in the consolidated condition. The
solid-to-liquid ratio can be 1:1 to 1:5. As described, the weight
ratio of the biomass material 11 and the hot compressed water 15
both to be fed into the device main body 42A is made 1:1 to 1:10,
thereby reducing the heat necessary for the hydrothermal
decomposition apparatus.
Further, by controlling the solid-to-liquid weight ratio inside the
device main body 42A, the conditions for hydrothermal decomposition
are stabilized, and the biomass solid residue 17 is stably
discharged from the biomass discharger 51.
By causing the biomass material 11 and the hot compressed water 15
to countercurrently contact with each other inside the hydrothermal
decomposition apparatus 41-1A, the solid-liquid separation is
performed. This reduces the amount of excessively decomposed
products to be brought into the solid, cellulose. Because lignin
components and the like are precipitated at low temperatures, the
separation is difficult at low temperatures. Thus, after the
hydrothermal decomposition, the decomposed products are taken out
from the reaction system and subjected to the separation. In this
way, it is possible to reduce the heat loss when flush occurs due
to a transition from a high temperature and high pressure condition
to a normal temperature and normal pressure condition. Further, the
discharged liquid containing the decomposed products is separated
with improved efficiency. This arrangement is realized considering
the fact that the hydrothermal decomposition products are
polysaccharide components precipitated at low temperatures and
therefore the separation is hardly carried out at low
temperatures.
According to the present embodiment, the weight of the biomass
material 11 to be fed into the hydrothermal decomposition apparatus
41-1A is increased, relative to the weight of the hot compressed
water 15. This enables reduction in the apparatus size, thus
contributing to improve economic efficiency.
Inside the hydrothermal decomposition apparatus 41-1A, the
temperature of the biomass material 11 is increased by causing it
to contact the hot compressed water 15 in the device main body 42A
and directly exchanging the heat. The temperature may be increased
by using steam or the like from the outside as necessary.
Alternatively, saturated steam may be directly fed into the device
main body 42, instead of the hot water.
In the present embodiment, the biomass feeder 31 employs a
mechanism for feeding the biomass material 11, including a piston
pump 31a. With this arrangement, the biomass feeder 31 feeds the
solid biomass material 11 under normal pressure to under increased
pressure. By using the piston pump 31a and applying pressure with
the piston, the biomass material 11 is reliably fed into the device
main body 42A.
Specifically, use of the piston pump 31a enables the solid in the
counter-current flow of solid and liquid, i.e., the biomass
material 11, to be moved by operation of the piston pump 31a,
without providing a rotational moving unit or the like for moving
the solid inside the device main body 42A. Further, use of the
piston pump 31a also enables control of the density inside the
device main body 42A (the solid-to-liquid weight ratio).
Specifically, it is possible to control the retention time of the
hot compressed water inside the device main body 42A.
The biomass discharger 51 employs a feeding mechanism including a
screw feeder 52a and a hydraulic cylinder 52b. This enables the
solid reacted inside the hydrothermal decomposition apparatus 41-1A
to be compressed, so that a biomass plug 53 is formed. The biomass
plug 53 serves as a material seal for keeping the pressure inside
the hydrothermal decomposition apparatus 41-1A. Gradually pressed
by the screw feeder 52a, the biomass under the increased pressure
can be gradually discharged from an edge of the hydraulic cylinder
52b to under the normal pressure. When the biomass solid residue 17
compressed, the residual water is removed from the biomass plug
53.
This dewatered solution 54 includes components soluble in hot
compressed water (lignin components and hemicellulose components).
Thus, the dewatered solution 54 is treated together with the
discharged hot water 16.
As a result, it is possible to dewater the hot compressed water
containing the components soluble in the hot compressed water and
normally accompanying the biomass solid residue 17. This improves
the yield of pentose using hemicellulose components (described
later), while contributing to reduce accompanied hexose enzyme
inhibitors (e.g., lignin components).
Because the pressure is changed from increased pressure to normal
pressure inside the biomass discharger 51, the biomass solid
residue 17 to be discharged is steam-exploded, causing breakage of
its fiber structure. This improves the efficiency of enzymatic
saccharification in the subsequent process.
The biomass discharger 51 can remove both of enzymatic
saccharification inhibitors and ethanol fermentation inhibitors, or
either of them, which are low-molecular-weight volatile
inhibitors.
In the present embodiment, the hot compressed water is discharged
at a portion near the inlet for feeding the biomass. Alternatively,
a liquid outlet for the hot compressed water may be provided in a
middle portion and the discharged liquid may be subjected to either
or both of heating and cooling so that an ideal temperature
distribution is plotted. Then, the discharged liquid may be fed
into the device main body 42A again.
The concentration of inhibitors such as furfral in the liquid may
be measured near a discharged section for the hot compressed water,
so that the feed amount of the hot compressed water 15 is
controlled based on the measured value. Alternatively, the sugar
concentration may be measured near the biomass discharger 51, so
that the feed amount of the hot compressed water 15 is controlled
based on the measured value.
In the present embodiment, the hot compressed water 15 may be fed
from one section. The present invention is not limited to this, and
the hot compressed water 15 may be fed from a plurality of sections
for temperature control.
In the present invention, by causing biomass material and hot
compressed water to countercurrently contact with each other, their
components are sequentially discharged in order of solubility in
the hot water. Further, due to the concentration gradient and the
temperature gradient from where the biomass is fed to where the hot
water is fed, excessive decomposition of hemicellulose components
is prevented. As a result, pentose components can be recovered
efficiently. Further, by causing the biomass material and the hot
compressed water to countercurrently contact with each other, the
heat is recovered, which is preferable in view of system
efficiency.
FIG. 2 depicts a modification of the present embodiment. As shown
in FIG. 2, a hydrothermal decomposition apparatus 41-1B is a
vertical type of the horizontal type shown in FIG. 1. As shown in
FIG. 2, the biomass feeder 31 is provided near a lower end of the
device main body 42A, so that the biomass material 11 is fed from
the lower end, while the hot compressed water 15 is fed from an
upper end thereof. By causing the biomass material 11 and the hot
compressed water 15 to countercurrently contact with each other,
their components are sequentially discharged as the discharged hot
water 16, in order of solubility in the hot compressed water 15.
Further, the biomass solid residue 17 is discharged from the
biomass discharger 51 provided near the upper end.
In the present embodiment, the device main body is arranged as a
vertical type. The present invention is not limited to this, and
the device main body may be a slanted type. The device main body
may be arranged as a slanted type or a vertical type, because it is
preferable regarding that the gas resulting from the hydrothermal
decomposition reaction, the gas brought into the biomass material,
and the like can be released quickly from the upper side. This
arrangement is also preferable in view of the discharging
efficiency, because decomposed products are discharged with the hot
compressed water 15 and therefore the concentration of the
discharged materials is increased from the upper side to the lower
side.
FIG. 3 depicts a modification of the present embodiment. In a
hydrothermal decomposition apparatus 41-1C shown in FIG. 3, the
dewatered solution 54, separated in the biomass discharger 51, is
fed again into the device main body 42A. This arrangement reduces
the amount of the hot compressed water to be fed into the
apparatus. Further, a desirable counter-current flow is
realized.
FIG. 4 depicts another modification of the present embodiment. As
shown in FIG. 4, a hydrothermal decomposition apparatus 41-1D
includes an excess water removal line 32, so that excess water 33
contained in the biomass is removed from the section for feeding
the biomass material 11 into the device main body 42A. The excess
water may be used to make the biomass material 11 wet.
Specifically, an excess water outlet 32a is provided away from a
liquid outlet 16a for the discharged hot water 16-1, and the
pressure (P.sub.1) at the excess water outlet 32a is made greater
than the pressure (P.sub.2) at the liquid outlet 16a. In this way,
the amount of the liquid to be discharged is controlled. This
arrangement prevents the reverse flow and excessive decomposition,
while reducing the heat loss.
The liquid outlet for the discharged hot water may be provided at a
plurality of sections (two sections 16a and 16b in the present
embodiment), and the properties of the discharged hot water at the
liquid outlet(s) and/or the properties of the biomass solid residue
may be measured. Then, based on the measured values, the liquid
outlet(s) for the discharged hot water may be changed
appropriately. In this way, the decomposition time is
controlled.
Further, a hot water inlet for the hot compressed water may be
provided at a plurality of sections (two sections 15a and 15b in
the present embodiment), and either or both of the properties of
the discharged hot water at the liquid outlet(s) and the properties
of the solid at the outlet may be measured. Then, based on the
measured values, the liquid outlet(s) for the discharged hot water
may be changed. In this way, the decomposition time is
controlled.
The feed amount of the biomass material 11 and the amount of the
discharged hot water at the liquid outlet(s) may be controlled so
that the solid-to-liquid weight ratio becomes a predetermined value
in the hydrothermal decomposition apparatus 41-1D.
FIG. 5 depicts still another modification of the present
embodiment. As shown in FIG. 5, a rotating stirring unit 61-2 may
be provided inside a device main body 42-2 so that the biomass
material 11 and the hot compressed water 15 may actively and
countercurrently contact with each other to be mixed and
stirred.
The rotating stirring unit 61-2 may have grooves formed thereon, or
may be installed at various pitches. Further, the rotating stirring
unit 61-2 may have screws in series at multiple stages, so that
each screw performs stirring individually.
Further, a filter unit 71 is provided through which the hot water
16 is discharged from the device main body 42-2, as shown in FIG.
5.
With straw biomass for example, its consolidated layer with a
thickness of a several centimeters can serve as a material seal.
The consolidated layer having a thickness equal to or less than
that thickness allows the liquid to pass therethrough, thus serving
as a self filter and enabling the liquid-solid separation at the
liquid outlet(s). Alternatively, a scraper mechanism (not shown)
for maintaining a predetermined thickness may be provided. In
addition to the self filter, a sand filtration filter may be
provided.
The scraper mechanism may be controlled by the pressure at the
liquid outlet(s).
FIG. 6 depicts still another modification of the present
embodiment. As shown in FIG. 6, a device main body 42-3 of a
hydrothermal decomposition apparatus 41-3 includes load cells 61a
and 61b as units each monitoring a concentration of the solid
inside the device main body 42-3. The load cells 61a and 61b detect
the weight of the solid, and change the rotation number and the
rotation direction of the paddles, so as to control the
concentration. In this way, the reaction efficiency is
improved.
Referring to FIGS. 7 and 8, the following describes an injection
method using a piston pump as a pressing unit, for injecting the
biomass material 11 into the device main body 42-3. As a pressing
unit, for example, a slurry pump or a screw feeder may be used
appropriately, other than the piston pump.
As shown in FIG. 7, the biomass material 11, which has been made
wet, is consolidated in the cylinder. If a consolidation force is
equal to or less than a set value, air and excess water are
discharged from an opened air/excess water discharge valve V.sub.1.
When the consolidation force reaches the set value, the air/excess
water discharge valve V.sub.1 is closed. With this arrangement, the
biomass material 11 may be filled via a gate valve 34 into the
device main body 42A of the hydrothermal decomposition
apparatus.
When the biomass material is a dried material (containing little
water), the material is consolidated in the cylinder. If a
consolidation force is equal to or less than a set value, air is
discharged from the opened air/excess water discharge valve
V.sub.1. When the consolidation force reaches the set value, water
is fed from a water feeding valve V.sub.2, excess water is
discharged from the air/excess water discharge valve V.sub.1, and
the both valves are closed. With this arrangement, the biomass
material 11 may be filled via the gate valve 34 into the device
main body 42A of the hydrothermal decomposition apparatus.
In the first embodiment, constituting elements of the biomass
hydrothermal decomposition apparatus are described individually
with reference to FIGS. 1 to 8. These elements may be combined
appropriately.
Second Embodiment
With reference to the drawings, the following describes a system of
producing an organic material, i.e., alcohol, with use of biomass
material according to an embodiment of the present invention. FIG.
10 is a schematic of an organic material production system using
biomass material according to the embodiment. As shown in FIG. 10,
an alcohol production system 10-1 using biomass material according
to the present embodiment includes: a pretreatment device 12 that
pulverizes the biomass material 11; the hydrothermal decomposition
apparatus 41-1A (shown in FIG. 1) that hydrothermally decomposes
pulverized biomass 13 by causing it to countercurrently contact the
hot compressed water 15, transfers lignin components and
hemicellulose components into the hot compressed water 15, and
separates the lignin components and the hemicellulose components
from the biomass; a first enzymatic hydrolysis device 19-1 that
treats cellulose in the biomass solid residue 17, discharged from
the hydrothermal decomposition apparatus 41-1A, with an enzyme
(cellulase) 18-1 to enzymatically hydrolyze it to a sugar solution
containing hexose; a first alcohol fermenter 21-1 that produces an
alcohol (ethanol in the present embodiment) by fermentation using a
first sugar solution (hexose) 20-1 obtained by the first enzymatic
hydrolysis device 19-1; and a first refiner 25-1 that refines a
first alcohol fermentation liquid 22-1, so as to separate it into a
target product, i.e., ethanol 23, and a residue 24-1.
According to the present invention, in the hydrothermal
decomposition apparatus 41-1A shown in FIG. 1, use of the
counter-current flow transfers lignin components and hemicellulose
components to the liquid phase, i.e., the hot compressed water 15,
while allowing cellulose to remain in the solid, i.e., the biomass
solid residue 17. In this way, the first sugar solution (hexose)
20-1 is obtained at the first enzymatic hydrolysis device 19-1 for
performing enzymatic saccharification. Accordingly, it is possible
to establish a fermentation process suitable for a hexose
(fermentation suitable for an end product: in the present
embodiment, fermentation for obtaining the ethanol 23 using the
first alcohol fermenter 21-1).
Although the present embodiment describes an example that an
alcohol, ethanol, is obtained by fermentation, the present
invention is not limited to this example. Other than alcohols,
substitutes for petroleum used as chemical product material, or
amino acids used as food and feed materials can be obtained with a
fermenter.
Examples of industrial products produced from a sugar solution as a
base material may include liquefied petroleum gas (LPG), auto fuel,
aircraft jet fuel, heating oil, diesel oil, various types of heavy
oils, fuel gas, naphtha, and naphtha decomposed products such as
ethylene glycol, ethanolamine, alcohol ethoxylate, vinyl chloride
polymer, alkylaluminum, polyvinyl acetate (PVA), vinyl acetate
emulsion, polystyrene, polyethylene, polypropylene, polycarbonate,
methyl methacrylate (MMA) resin, nylon, and polyester. Thus,
substitutes for industrial products derived from crude oil, which
is fossil fuel, and sugar solution derived from biomass, which is a
biomass material for producing such substitutes, can be used
efficiently.
Third Embodiment
With reference to the drawings, the following describes a system of
producing an organic material, i.e., alcohol, with use of biomass
material according to an embodiment of the present invention. FIG.
11 is a schematic of a system of producing an organic material,
i.e., alcohol, with use of biomass material according to the
present embodiment. As shown in FIG. 11, an alcohol production
system 10-2 using biomass material according to the present
embodiment is constituted by the alcohol production system 10-1
shown in FIG. 10 that includes a second enzymatic hydrolysis device
19-2. The second enzymatic hydrolysis device 19-2 treats
hemicellulose components, transferred into the hot water 16
discharged from the hydrothermal decomposition apparatus 41-1A,
with an enzyme to enzymatically hydrolyze it to a sugar solution
20-2 containing pentose. Two enzymatic hydrolysis devices, two
alcohol fermenters, and two refiners are provided (the first
enzymatic hydrolysis device 19-1, the second enzymatic hydrolysis
device 19-2, the first alcohol fermenter 21-1, a second alcohol
fermenter 21-2, the first refiner 25-1, and a second refiner 25-2).
The ethanol 23 is obtained by performing an enzymatic hydrolysis
process, an alcohol fermentation process, and an alcohol refining
process that are suitable for each of the first sugar solution
(hexose) 20-1 and a second sugar solution (pentose) 20-2.
In the present embodiment, the ethanol 23 can be produced by
fermentation, using the second sugar solution (pentose) 20-2
obtained by the second enzymatic hydrolysis device 19-2.
The discharged hot water is not necessarily treated in a separate
system. For example, processes subsequent to the enzymatic
hydrolysis devices, processes subsequent to the alcohol fermenters,
or processes subsequent to the refiners may be arranged as common
processes, or other modification may be made appropriately.
According to the present invention, in the hydrothermal
decomposition apparatus 41-1A, use of the counter-current flow
allows cellulose to remain in the solid phase which is the biomass
solid residue 17. Accordingly, the first sugar solution (hexose)
20-1 is obtained by the first enzymatic hydrolysis device 19-1 for
performing enzymatic saccharification. Further, hemicellulose
components dissolved in the liquid phase which is the hot
compressed water 15, are separated therefrom as the discharged hot
water 16, so that the second sugar solution (pentose) 20-2 is
obtained by the second enzymatic hydrolysis device 19-2 for
separately performing enzymatic saccharification. This enables the
solid and the liquid to be separated efficiently and saccharified
individually. Accordingly, fermentation processes suitable for
hexose and pentose (fermentation suitable for an end product: e.g.,
ethanol fermentation) can be established.
As such, in the hydrothermal decomposition apparatus 41-1A, use of
the counter-current flow transfers a side reaction product and a
lignin component soluble in hot compressed water, both acting as
inhibitors during enzymatic saccharification reaction for obtaining
hexose, to the hot compressed water 15. Accordingly, the
cellulose-based biomass solid residue 17 is obtained, improving the
yield of hexose in the subsequent enzymatic saccharification
reaction.
On the other hand, hemicellulose components contained in the
separated discharged hot water 16 is saccharified later at the
second enzymatic hydrolysis device 19-2, so that a sugar solution
containing pentose can be obtained. Then, by using yeasts etc.
suitable for hexose and pentose, ethanol can be obtained by
fermentation individually and efficiently.
As described above, the present invention provides: a biomass
hydrothermal decomposition apparatus and a method thereof that can
produce, by transferring cellulose-based components and
hemicellulose components from the biomass material to the hot
compressed water and separating them from each other, sugar
solutions suitable for the cellulose-based components and the
hemicellulose components (hexose sugar solution and pentose sugar
solution), and that can efficiently produce, using the sugar
solutions as substrate materials, various types of organic
materials (e.g., alcohols, substitutes for petroleum, or amino
acids); and an organic material production system using biomass
material. However, a conventional technology causes a phenomenon
that a side reaction product inhibits enzymatic saccharification
and a sugar yield is reduced.
Industrial Applicability
As described, according to the present invention, a hydrothermal
decomposition apparatus separates cellulose-based components from
biomass material, so as to efficiently produce a sugar solution.
Further, using the sugar solution as a substrate material, various
types of organic materials (e.g., alcohols, substitutes for
petroleum, or amino acids) can be efficiently produced.
* * * * *
References